Method of forming collapsed carton blank



Aug. 14, 1962 R. v. BURT METHOD OF FORMING COLLAPSED CARTON BLANK 2 Sheets-Sheet 1 Filed June 22, 1960 Firs. Z

INVENTOR. Passer 1/ 5027,

ATTOFZN EV.

Aug. 14, 1962 R. v. BURT METHOD OF FORMING COLLAPSED CARTON BLANK 2 Sheets-Sheet 2 Filed June 22, 1960 INVENTOR. [055/27 M 50/27;

gwuakvl States hi Hi6 This invention relates to a method of forming finished overwrapped carton blanks in collapsed condition and, more particularly, to a method of forming a carton blank simultaneously which is composed of an outer wrapper and an inner liner having an exposed opening tab protruding through or beyond the outer Wrapper.

It is common practice to package articles in cartons formed of paperboard and the like by squaring up the collapsed carton, inserting the article through an open end and then folding, tucking and sealing the end flaps. Many types of commercial machines are available for this purpose. Frequently, however, it is desired to overwrap the packed carton with a decorative outer wrapper, film or foil and this requires the use of a second machine for performing the overwrap operation. There have been attempts to form a collapsed carton with an overwrap but usually this is done in two stages and requires pregluing of the inner carton into tubular form. That is, the inner carton is first formed and adhesively adhered at an overlapping glue flap and then the outer wrapper is placed around it. The formation of a collapsed carton in this fashion does not permit the inclusion of a built-in opening device such as a tear tab.

It is an object of this invention to form collapsed carton blanks by simultaneously folding an inner liner and outer wrapper into proper relationship and then sealing the outer wrapper to maintain the blank in that condition.

Another object of this invention is the provision of a method for forming overwrapped carton blanks of this character which can be accomplished without adhesively adhering the inner liner in order to maintain it in its folded condition.

A further object of this invention is a method of forming an overwrapped carton blank simultaneously with the outer wrapper in which an opening tab integral with the inner liner is provided which protrudes through or beyond the outer wrapper.

Briefly stated, in accordance with one aspect of the invention, a method of forming a package blank is provided which comprises the steps of superposing a substantially rectangular outer wrapper with an inner liner composed of a plurality of side-by-side panels which are separated by scores so that a tear tab panel having an opening tab is provided at one end of the liner blank; the outer wrapper and inner liner are positioned with respect to one another so that the opening tab is exposed through or protrudes slightly beyond one edge of the oute wrapper; the liner and superposed portion of the wrapper are folded over on one of the score lines separating adjoining panels but without covering the tear tab panel; a second fold is made of the liner and superposed portion of the outer wrapper at the second score line from the first fold so that the corner portions of the outer Wrapper are overlapped and the tear tab is exposed through an opening in the outer wrapper or protrudes beyond the edge of the overlapped outer wrapper; the overlapped corner portions of the outer wrapper are then adhered to complete the formation of the collapsed package blank.

The manner of accomplishing these and other objects of the invention will be apparent to one skilled in the art atentffice 3,@ i9,959 Patented Aug. 14-, 1962 upon reading the specification and claims. The objects are accomplished by the sequence of operation and steps which are described hereinafter in certain exemplary embodiments. Reference is made to the accompanying drawings wherein:

FIGURE 1 is a plan view of the superposed outer wrapper and inner liner with the opening tab extending slightly beyond one edge of the outer wrapper; and

FIGURE 2 is a plan vieW similar to FIGURE 1 after making the first fold; and

FIGURE 3 is a plan view of the finished package blank after making the second fold and adhering the overlapped corners of the outer wrapper; and

FIGURE 4 is a perspective view of the blank shown in FIGURE 3 after being squared up into tubular form to receive an article; and

FiGURE 5 is a perspective view of the package after an article has been inserted and the end tucks made; and

FIGURE 6 is a perspective view of the finished package; and

FIGURE 7 is a plan view of a partially completed package blank after making the first fold on a different score line; and

FIGURE 8 is the finished package blank of FIGURE 7 after making the second fold and adhering the overlapped corner portions of the outer wrapper; and

FIGURE 9 is a plan view of the superposed outer wrapper and inner liner wherein the opening tab is exposed through a slot in the outer wrapper; and

FIGURE 10 is a plan View of the finished package blank made from the superposed liner and outer wrapper of FIGURE 9; and

FIGURE 11 is a perspective view of the finished pack age made from the package blank of FIGURE 10.

Referring now to the drawing and particularly to FIG- URE 1, there is shown a liner blank 10 which may be formed from cardboard, paperboard or similar materials having reasonable stiffness and resistance to bending. The liner blank id is divided into a tear tab panel 11, a top panel 12, a back panel 13, a bottom. panel 14, and a front panel 15 by means of the substantially parallel score lines 16, 17, i3 and i9. Pairs of end tabs 20, 21 and 22, 23 extend from either side of the liner blank It) and can be articulated on the score lines 24, 25, 25 and 27 said score lines being substantially coextensive with the edges of the top panel 12 and bottom panel 14. The tear tab panel 11 has bevelled edges 28 and 29 which are substantially parallel to the sides of the notch 30 in the front panel 15. This permits the tear tab panel 11 to nest in the notch 30 in order that the liner blanks 10 can be cut in end-to-end relation from a continuous web with a minimum of scrap loss.

The outer wrapper 31 is substantially rectangular in form and can be formed from any commercially available thin film, such as cellophane, metal foil, paper lined foil or paper and the like. Preferably, the outer wrapper material is or" heat sealing character as this permits the formation of the package blank at substantially high speeds and without the need for adhesives.

The liner blank 10 is superposed upon the outer wrapper 31 in substantially the relationship shown in FIG- URE 1 so that the outside or printed surfaces of the wrapper 31 faces downwardly or away from the inner liner lit. The liner blank 10 and the outer wraper 31 may be adhered to one another to maintain their proper relationship although this is not necessary in order to practice the method successfully. In this embodiment, the outer end of the tear tab panel 1].! must extend beyond the edge 32 of the outer Wrapper 31 in order to form an opening tab 33. The opening tab 33 as described herein will be understood to be composed of that portion of the tear tab panel 11 which is not superposed with a portion of the outer wrapper 31.

As a next step, the front panel 15 together with the end tabs 22 and 2 3 as well as that portion of the outer wrapper 3 1 which overlies the front panel 15 and end tabs 22 and 23 are folded along the score line 19 to a position as indicated in FIGURE 2. In this condition, the inner surface of the front panel 15 is contiguous to the adjoining portion of the inner surface of the bottom panel 14 and the inner surfaces of the end tabs 22 and 23 are contiguous to a portion of the inner surface of the outer wrapper 31 as will be appreciated by viewing FIGURE 2.

As a further step, the liner blank is folded over at the score line 17 together with the superposed portion of the outer wrapper 31. When this fold is completed, the package blank takes the form shown in FIGURE 3 so that the inner surface of the top panel 12 is contiguous to the inner surface of the back panel 13 and a portion of the bottom panel 14. The inner surface of the tear tab panel 1 1 lies partially on the outer surface of the front panel and partially upon the end 34 of the outer wrapper. The opening tab 33 protrudes beyond the edge 32 in this condition, the corner portions of the outer Wrapper 31 are superposed as at 35 and 36 so that the collapsed package blank can be completed by sealing the overlapped corners either by the application of heat if a heat sealable outer wrapper is used or by the use of an adhesive if a non-heat sealable material is used.

The utility of this package blank is best illustrated by referring to FIGURES 4, 5 and 6. In FIGURE 4, the collapsed blank of FIGURE 3 has been squared up into tubular form so that the panels 12, 13, 14 and 15 are at substantially right angles with respect to one another. The article or commodity to be packaged can then be inserted through the open end 37 after which the end tucks 38 and 39 shown in FIGURE 5 can be formed at both ends (only one end shown). The package is completed by the formation of the end folds 40 and 41 as shown in FIGURE 6. Both ends would, of course, be finished in this fashion although only one end is shown in FIGURE 6 of the drawing. The end folds 40 and 41 are sealed by the application of heat when heat sealable outer wrapper material is used or when not, a suitable adhesive material can be used to accomplish this seal.

The finished package as illusrated in FIGURE 6 is substantially identical to the package described and claimed in the copending application of Robert V. Burt, Serial No. 798,736, filed March 11, 1959, which is also assigned to the same assignee as the assignee of the present invention.

The present method of forming package blanks is, of course, completely different from any prior art practices as it permits the formation of a flat overwrapped blank complete with an opening tab in a series of simple operations. It is then possible to erect, fill and complete the carton by the use of conventional cartoning equipment as, for example, a well known model CMC fully automatic cartoner as manufactured by the R. A. Jones & Co., Inc.

FIGURES 7 and 8 depict a modified method of forming the package blank or" this invention. It will be noted that in FIGURE 7 the first fold has been made at the score line 18 so that the inner faces of the bottom panel 14 and front panel 15 are contiguous to the inner faces of the top panel .12 and the back panel 13. The package blank is completed as shown in FIGURE 8 by folding the tear tab panel 11 and the superposed portion of the outer wrapper 31 along the score line 16 so that the corner portions of the outer wrapper 31 are superposed at 35 and 36 in which position they can be readily sealed either by heat or other means as heretofore described,

As in the previous embodiment, the opening tab 33 protrudes beyond the edge 32 of the outer wrapper. The package blank of FIGURE 8 can be erected, filled and have its ends sealed in much the same manner as previously described in connection with the package blank of FIGURE 3.

A further modification is illustrated in FIGURES 9, l0 and 11. The liner blank 14 shown in FIGURE 9 is substantially identical to that shown in FIGURE 1; therefore like reference numerals are used to identify the same or similar parts. The outer wrapper blank 31 is slotted at 42, the slot 42 being composed of parallel edges 43 and 4'4 and rounded ends 45 and 46 although other forms of slots or openings can be used. Thus when the inner liner 1t and outer wrapper 31 are superposed, the opening tab 33 will be exposed by extending into the slot 42 beyond the edge 43. The same sequence of steps is performed on the superposed liner blank 10 and outer wrapper 31 as heretofore described in order to form a finished package blank as illustrated in FIGURE 10 upon sealing the overlapping corner portions 35 and 36. The package blank of this embodiment is then capable of being erected, filled and have its ends tucked and folded as heretofore described in order to form the finished package illustrated in FIGURE 11.

While particular embodiments of the invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention and it is intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

VJhat is claimed as new is:

l. A method of forming a package blank which comprises providing a flat substantially rectangular outer wrapper, overlaying an inner liner blank composed of a plurality of panels separated by score lines and including a tear tab panel having an opening tab at one end, laying the inner liner on the outer wrapper so that the opening tab extends beyond an edge of the outer wrapper, folding over the liner and superposed portion of the wrapper at one of the score lines separating adjoining panels and without covering the tear tab panel, folding over the liner and superposed portion of the wrapper at a second score line located two score lines over from the first fold so that the corner portions of the outer wrapper are overlapped and the tear tab is exposed, thereafter sealing the outer wrapper at said overlapped corners to form a collapsed package blank.

2. A method of forming a package blank which comprises providing a flat substantially rectangular outer wrapper having heat sealing characteristics, superposing an inner liner blank composed of a plurality of panels separated by a plurality of substantially parallel score lines and including a tear tab panel having an opening tab at one end, positioning the outer wrapper and inner liner so that the opening tab extends beyond an edge of the outer wrapper, folding over the inner liner and superposed portion of the outer wrapper along one of the said score lines but without covering the tear tab panel, folding over the inner liner and superposed portion of the outer wrapper along the score line which is located two score lines over from the first fold so that the corner portions of the outer wrapper are overlapped and the tear tab is exposed, thereafter heat sealing the overlapped corners of said outer wrapper to form a collapsed package blank.

3. A method of forming a flat overwrapped package lank from an inner liner blank and an outer wrapper blank wherein the liner blank is divided by a plurality of substantially parallel scores into a plurality of sideby-side panels including successively a front panel, bottom panel, back panel, top panel and a tear tab panel, the steps comprising superposing the inner liner blank and the outer wrapper blank so that an edge of the tear aoeaose tab panel extends beyond an edge of the outer wrapper blank, folding over the front panel and the superposed portion of the outer wrapper on a score line so that its inner surface is contiguous to one of the panels intermediate the tear tab panel and the front panel, folding over the tear tab panel and the superposed portion of the outer wrapper so that the tear tab panel is contiguous to the exposed portion of the outer surface of the front panel and the portion of the outer Wrapper blank overlying the front panel and thereby superposing the corner portions of the outer wrapper blank, thereafter sealing the superposed portions of the outer wrapper blank on both sides of the tear tab panel to form the finished blank.

4. A method of forming a package blank which comprises providing a flat substantially rectangular outer wrapper having heat sealing characteristics, superposing an inner liner blank composed of a plurality of panels separated by substantially parallel scores, said panels including successively a front panel, bottom panel, back panel, top panel and a tear tab panel having an opening tab at its end, positioning the inner liner on said outer Wrapper so that the opening tab is exposed beyond an edge of the outer Wrapper, folding over the front panel and the superposed portion of the outer wrapper along the score line separating it from the bottom. panel, folding over the top panel and tear tab panel along the score line separating the top panel and back panel so that the corner portions of the outer wrapper are superposed and the tear tab protrudes from an edge of the outer Wrapper,

thereafter heat sealing the overlapped corners of said outer wrapper to form a collapsed package blank.

5. A method of for-minga package blank which comprises providing a flat substantially rectangular outer Wrapper having heat sealing characteristics, superposing an inner liner blank composed of a plurality of panels separated by substantially parallel scores, said panels including successively a front panel, bottom panel, back panel, top panel and a tear tab panel having an opening tab at its end, positioning the inner liner on said outer Wrapper so that the opening tab is exposed beyond an edge of the outer Wrapper, folding over the front panel, the bottom panel and the superposed portion of the outer wrapper along the score line separating the bottom panel and the back panel, folding over the tear tab panel and the superposed portion of the outer Wrapper along the score separating the tear tab panel from. the top panel so that the corner portions of the outer wrapper are superposed and the tear tab protrudes from an edge of the overlapped outer Wrapper thereafter heat sealing the superposed corners of the outer Wrapper to form a collapsed package blank.

Bergstein Dec. 21, 1954 Vergobbi Aug. 23, 1960 

